WO2012072513A2 - Améliorations dans la régulation de flux de chaleur pour le moulage d'un équipement de fond - Google Patents
Améliorations dans la régulation de flux de chaleur pour le moulage d'un équipement de fond Download PDFInfo
- Publication number
- WO2012072513A2 WO2012072513A2 PCT/EP2011/071038 EP2011071038W WO2012072513A2 WO 2012072513 A2 WO2012072513 A2 WO 2012072513A2 EP 2011071038 W EP2011071038 W EP 2011071038W WO 2012072513 A2 WO2012072513 A2 WO 2012072513A2
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- mold
- molded
- container
- molding
- assembly
- Prior art date
Links
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- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 description 4
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- 229910052582 BN Inorganic materials 0.000 description 1
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C21/00—Flasks; Accessories therefor
- B22C21/12—Accessories
- B22C21/14—Accessories for reinforcing or securing moulding materials or cores, e.g. gaggers, chaplets, pins, bars
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/10—Cores; Manufacture or installation of cores
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D19/00—Casting in, on, or around objects which form part of the product
- B22D19/14—Casting in, on, or around objects which form part of the product the objects being filamentary or particulate in form
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D27/00—Treating the metal in the mould while it is molten or ductile ; Pressure or vacuum casting
- B22D27/04—Influencing the temperature of the metal, e.g. by heating or cooling the mould
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
- B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/02—Compacting only
- B22F3/03—Press-moulding apparatus therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
- B29C43/18—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B10/00—Drill bits
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/757—Moulds, cores, dies
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/772—Articles characterised by their shape and not otherwise provided for
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y80/00—Products made by additive manufacturing
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Definitions
- the present invention relates to methods of
- Embodiments of the invention may be concerned with the use of printed bodies formed by 3D printing, which bodies constitute or include molds, which may form part of a mold assembly for molding or casting do nhole equipment or components thereof.
- Rotary drill bits are frequently used to drill oil and gas wells, geothermal wells and water wells.
- Rotary drill bits may be generally classified as rotary cone or roller cone drill bits and fixed cutter drilling equipment or drag bits.
- Fixed cutter drill bits or drag bits are often formed with a bit body having cutting elements or inserts disposed at select locations of exterior portions of the bit body. Fluid flow passageways are typically formed in the bit body to allow communication of drilling fluids from
- Fixed cutter drill bits generally include a metal shank operable for engagement with a drill string or drill pipe.
- Various types of steel alloys may be used to form a metal shank.
- a bit head may be attached to an associated shank to form a resulting bit body.
- a bit head may be formed from various types of steel alloys satisfactory for use in drilling a wellbore through a downhole formation.
- the resulting bit body may sometimes be described as a "steel bit body.”
- a bit head may be formed by molding hard, refractory materials with a metal blank. A steel shank may be attached to the metal blank.
- matrix bit body may be described as a "matrix bit body.”
- Fixed cutter drill bits or drag bits formed with matrix bit bodies may sometimes be referred to as “matrix drill bits.”
- machining processes have been used to fabricate molds from various types of raw material blanks.
- graphite based materials in the form of solid, cylindrical blanks have been machined to form a mold cavity with dimensions and configurations that represent a negative image of a bit head for an associated matrix drill bit.
- Matrix drill bits are often formed by placing loose infiltration material or matrix material (sometimes referred to as "matrix powder") into a mold and infiltrating the matrix material with a binder such as a copper alloy. Other metallic alloys may also be used as a binder. Infiltration materials may include various refractory materials.
- preformed metal blank or bit blank may also be placed in the mold to provide reinforcement for a resulting matrix bit head.
- the moid may be formed by milling a block of material such as graphite to define a mold cavity with features
- passageways may be provided by shaping the mold cavity
- An associated metal shank may be attached to the bit blank after the matrix bit head has been removed from the mold.
- the metal shank may be used to attach of the resulting matrix drill bit with a drill string.
- three dimensional (3D) printing equipment and techniques have been used in combination with three dimensional (3D) design data associated with a wide variety of well drilling equipment and well completion equipment to form molds for producing various components associated with such equipment.
- refractory materials infiltration materials and/or matrix materials, typically in a powder form, may be placed in such molds.
- molten steel alloys or other molten metal alloys may be poured into such molds .
- U.S. Pat. No. 5,204,055 entitled 3-Dimensional Printing Techniques and Related Patents discusses various techniques such as ink et printing to deposit thin layers of material and inject binder material to bond each layer of powder material. Such techniques have been used to "print" molds satisfactory for metal casting of relatively complex configurations.
- U.S. Pat. No. 7,070,734 entitled “Blended Powder Solid-Supersolidus Liquid Phase Sentencing" and U.S. Pat. No. 7,087,109 entitled “Three Dimensional Printing Material System and Method” also disclose various features of 3D printing equipment which may be used with 3D design data. Another technique for 3D printing is known as
- SLS Selective Laser Sintering
- three dimensional (3D) computer aided design (CAD) data associated with fixed, cutter drill bits may be used to produce respective molds each having a moid cavity that is essentially a "negative image" of various portions of each fixed cutter drill bit.
- Such molds may be used to form, a matrix bit head or a steel bit head for a respective fixed cutter drill bit.
- U.S. Pat. No. 6,296,069 entitled “Bladed Drill Bit with Centrally Distributed Diamond Cutters” and U.S. Pat. No. 6,302,224 entitled “Drag-Bit Drilling with Multiaxial Tooth Inserts” show various examples of blades and/or cutting elements which may be used with a matrix bit body.
- Various components of other well tools may also be molded as matrix bodies.
- Calnan et al. contemplate that providing high thermal conductivity proximate a first end or bottom portion of a mold may improve heat transfer during heating and cooling of materials disposed within the moid. Thermal conductivity may be relatively low proximate a second end or top portion of the moid, so that that portion of the mold will function as an insulator for better control of heating and/or cooling of materials disposed within the moid.
- Calnan et al . envision that, for some applications, two or more layers of sand or other materials with different heat transfer characteristics may be used to form molds. It is to be understood that the two or more layers in question are two or more of the same horizontal layers of mold material which are sequentially deposited and. built up in the 3D printing process by which the mold is formed .
- Calnan et al further propose to form a mold having variations in electrical conductivity to accommodate varying heating and/or cooling rates of materials disposed within the moid.
- one or more portions of the mold may be formed from materials having electrical conductivity characteristics compatible with an associated microwave heating system or an induction heating system. As a result, such portions of the mold may be heated to a higher temperature
- Calnan et al. contemplate placing degassing channels within a mold to allow degassing or off gassing of materials disposed within the mold, as well as providing fluid flow channels on interior and/or exterior portions of a mold to heat and/or cool materials disposed within the mold. Various types of liquids and/or gases may be circulated through such fluid flow channels.
- a method of designing a mold the mold being at least part of a unitary body to be formed from a plurality of layers by 3D printing, the method
- the method further comprises:
- the outer surface of the mold corresponding at least in part to an inner surface of a container in which the moid may be installed as part of a mold assembly, the outer surface of the moid being defined so as to minimize the thickness of the mold between the inner surface and the outer surface of one or more parts of the mold whilst the mold, and molded object remain removable from the container after molding the object.
- the thickness of the mold may be minimized whilst further maintaining a minimum strength of the mold as is required for handling the mold and for molding the object without breaking.
- the material for each part of the mold may be selected based on a
- the material for each part of the mold may be selected by initially designing the mold to be formed entirely of the first material or entirely of the second material, and then substituting that material with the second material or the first material, respectively, in one or more parts in order to increase or decrease, respecti ely, the thermal conductivity of the mold in those one or more parts.
- the second material may be excitable by electromagnetic radiation to generate heat and thereby to act as a heat source .
- the mold may be initially designed to be formed entirely of the first material, and then one or more parts of the mold re-designed to be formed of said second, material in order to control the distribution of temperature and/or the direction of heat flow through the mold during molding of the object.
- the material for each part of the mold may be selected, at least in part, based on the heat flow
- the object to be molded in the embodiments of the first aspect of the invention may be an object selected from the list including: a steel bit head; a matrix bit head; a drill bit; and a piece or component of downhole equipment.
- a unitary body forme G rom a plurality of layers by 3D printing comprising a mold, wherein: the mold defines an internal surface
- At least a part of the mold is printed from a first material; at least another part of the mold is printed from a second material, the second material having a higher thermal and/or electrical
- At least one of the layers from which the mold is formed by 3D printing includes areas printed from each of the first and second materials .
- the moid may define an outer surface corresponding at least in part to an inner surface of a container in which the mold may be
- one or more parts of the mold having a thickness between the inner and outer walls that is minimized whilst still permitting the mold and molded object to remain removable from the container after molding the object.
- the second material is incorporated in parts of the mold where increased heat flow into or out of the material from which the object is to be molded is desired in order to control the direction of heating and/or cooling and/or solidification of the material from which the object is to be molded.
- the second material is excitable by electromagnetic radiation to generate heat and thereby to act as a heat source.
- the object to be molded may be an object selected from the list including: a steel bit head; a matrix bit head; a drill bit; and a piece or component of downhole equipment.
- a method of printing a unitary body from a plurality of layers by 3D printing comprising" a mold having an internal surfa.ce corresponding to at least part of an external surface of an object to be molded in the mold, the method comprising depositing and bonding in selected areas a plurality of layers of materials to form the body, wherein: the materials include a first mold material from which at least part of the moid is to be printed and a second mold material from which at least another part of the mold is to be printed, the second mold material having a higher thermal and/or electrical
- the materials from which the body is formed are selectively deposited in specified areas in each layer.
- the materials from which the body is formed are selectively bonded in specified areas in each layer .
- the object to be molded is an object selected from the list including; a steel bit head; a matri bit head; a drill bit; and a piece or component of downhole equipment .
- a method of designing a mold assembly including a container and a moid, at least portions of an outer surface of the mold corresponding to an inner surface of the container such that the container will support the mold therein, in use of the mold for molding an object, the mold assembly defining a mold cavity
- the method including: specifying at least one material from which the mold is to be formed from a
- the space is between the mold and the inside of the container.
- the at least another material is positioned in a space created by a displacement that forms part of the mold, the displacement defining a negative image of at least part of a recessed portion of the object to be molded, wherein the method includes at least partially minimizing the wall thickness of the displacement so as to form the space
- the mold includes an elongate displacement inside the mold cavity to define a fluid passageway through the object to be molded, with the space being defined inside the elongate displacement.
- the space provides a flow channel through which heating or cooling fluids may be passed to control heat flow through the material from which an object is to be molded in the moid.
- the at least another material is
- the at least another material may form, part of a heat source for selectively supplying heat to the mold assembly.
- the at least another material may be excitable by electromagnetic radiation to generate heat and thereby to acr. as a heat source.
- the material for each part of the mold assembly may be selected based on the material or materials from which the object is to be molded.
- the material for each part of the mold assembly is selected based on a likelihood of molding defects occurring in the material from which the object is to be molded in related parts of the mold cavity during molding of the object.
- Still further embodiments of the fourth aspect of the invention include minimizing the thickness of the mold whilst ensuring that the moid and molded object remain removable from the container after molding the object, such that the container can be used more than once for molding an object.
- the thickness of the mold is minimized whilst further maintaining a minimum strength of the mold as is required for handling the mold for assembling the moid assembly and for molding the object without breaking.
- the object to be molded may be an object selected from the list including: a steel bit head; a matrix bit head; a drill bit; and a piece or component of do nhole equipment .
- a mold assembly including a container and a mold, at least portions of an outer surface of the mold corresponding to an inner surface of the
- the mold assembly defining a mold cavity substantially corresponding to the outer shape of the object to be molded, wherein: the mold is formed from a plurality of layers of at least one material by 3D printing; andat least another material is positioned in at least part of a space inside the container which is defined by the mold and is separate from the mold cavity, the other material having a thermal and/or electrical conductivity different from that of the one material.
- the space is between ohe mold and the inside of the container, in this case, the at least another material may be positioned in a space created by a displacement that forms part of the moid, the displacement defining a negative image of at least part of a recessed portion of the object to be molded, wherein the wall thickness of the displacement is at least partially minimized so as to form the space between the outer wall of the mold and the inner wall of the container .
- Further embodiments of the mold assembly of the fifth aspect of the invention may include an elongate displacement inside the mold cavity to define a fluid passageway through the object to be molded, the space being defined inside the elongate displacement and having therein che at least another material having a thermal and/or electrical conductivity different from that of the at least one material from which the mold is to be printed.
- the thickness of the mold is at least partially minimized whilst ensuring that the mold and molded object remain removable from, the container after molding the object.
- the at least another material forms part of a heat source for selectively supplying heat to the mold assembly.
- the at least another ma.terial may be excitable by electromagnetic radiation to generate heat and thereby to act as a heat source.
- the at least another material is positioned in contact with the mold.
- the object to be molded is an object selected from the list including: a steel bit head; a matrix bit head; a drill bit; and a piece or component of downhole equipment.
- a method of manufacturing a mold assembly including a container and a mold, at least portions of an outer surface of the mold corresponding to an inner surface of the container such that the container will support the mold therein, in use of the mold for molding an object, the mold assembly defining a mold cavity
- the method including: installing in the container (1) a mold formed from a plurality of layers of at least one material by 3D printing and (ii) at least another material positioned in a space defined by the mold inside the container, wherein the other material has a thermal and/or electrical conductivity different from that of the one material.
- the mold includes at least one elongate displacement which is installed inside the mold cavity to define a fluid
- a method of molding an object including heating and/or cooling a body of material in a mold assembly, the method including controlling the heating and/or cooling of the body of material by selectively
- the mold assembly includes a mold and the heat source is disposed in the mold or in a space
- selectively supplying neat includes (directly or indirectly) selectively controlling the rate at which heat is supplied by the heat source and/or selectively supplying heat for certain time periods and not supplying heat for other time periods, during the heating and/or cooling of the body.
- heat is supplied from the heat source by exciting the heat source by applying an electromagnetic field .
- the heat source includes an element selected from the list including: a thermally conductive channel for conducting heat into the mold assembly from a hotter region outside the mold assembly; an induction heating element; a glow bar; and a bar heater.
- the heat source is disposed in a
- a method of molding an object including heating and/or cooling a body of material in a mold designed according to the method of the first aspect of the present invention
- a method of molding an object including heating and/or cooling a body of material in a mold assembly including the unitary body of the second aspect of the present invention.
- a method of molding an object including heating and/or cooling a body of material in a mold assembly including a unitary body designed by the method of the third aspect of the present invention.
- a method of molding an object including heating and/or cooling a body of material in a mold assembly designed according to the method of the fourth aspect of the present invention.
- a method of molding an object including heating and/or cooling a body of material in a mold assembly according to the fifth aspect of the present invention .
- a heating device including a heat source for use in molding an object in a mold assembly, the heat source being disposed within a displacement forming part of the mold assembly for forming a recess in or flow passage through the object to be molded.
- the displacement is formed from consolidated sand.
- a method of molding an object comprising heating and/or cooling material from which the object is to be formed in a moid assembly that includes the heating device of the thirteenth aspect of the present invention, wherein the method includes controlling the heating and/or cooling, at least in part, by supplying heat to the mold assembly with the heating device.
- FIG. 1 is a schematic drawing showing a perspective view of a fixed cutter drill bit
- FIG. 2 is a schematic drawing showing a cross-sectional view through the drill bit of FIG. 1;
- FIG. 3 is a schematic drawing showing a cross-sectional view through a mold assembly that may be heated and cooled to mold the fixed cutter drill bit of FIGS. 1 and 2;
- FIG. 4 is a schematic drawing showing a partial cross- sectional view through the lower portion of the mold and container of the mold assembly shown in FIG. 3;
- FIG. 5A is a schematic drawing showing a perspective view of a mold which may be used to form a bit head for a fixed cutter rotary drill bit;
- FIG. 5B is a schematic drawing showing another
- FIG. 5C is a drawing in section taken along lines 5C-5C of FIG. 5B
- FIG. 5D is a schematic drawing in section taken along lines 5D-5D of FIG. 5C;
- FIG. 6 is a schematic drawing showing a perspective view of another mold which may be used to form a bit head for a fixed, cutter rotary drill bit;
- FIG. 7 is a schematic drawing showing a partially cutaway side view of the mold of Fig. 6 installed in a
- FIG. 8 is a schematic drawing showing a perspective view of a matrix bit head
- FIG. 9 is a schematic drawing showing a cross-sectional view through a mold assembly that may be heated and cooled, to mold a fixed cutter drill bit having the same shape as that of Fig. 1, but including transition regions between the different matrix materials;
- FIG. 10 is a schematic drawing showing a cross- sectional view through a mold assembly that may be heated and cooled to mold a fixed cutter drill bit, the mold assembly including heat sources to control the heating and/or cooling of the mold assembly;
- FIG. 11 is a schematic drawing showing an exploded perspective view of a mold formed of two segments to
- FIG. 12 is a schematic drawing showing a cross- sectional view through a printed body that includes, in the same layer, mold material and matrix material, the matrix material to be infiltrated to form a molded object, and further shows a thin barrier printed between the adjacent areas of mold material and matrix material.
- bit body for a rotary drill bit. Portions of the bit body formed in a mold may be referred to as a "bit head.” For some embodiments a "bit body” may generally be described as a bit head with a metal shank attached thereto. Some prior art references may refer to a bit head (as used in this
- bit bodies may be formed with an integral bit head and metal shank in accordance with teachings of the present disclosure.
- downhole tool and “downhole tools” may be used to describe well drilling equipment, well drilling tools, well completion equipment, well completion tools and/or associated components which may be manufactured using molds formed in accordance with teachings of the present disclosure.
- Examples of such well completion tools and/or associated components may include, but are not limited to, whipstocks, production packer components, float equipment, casing shoes, casing shoes with cutting structures, well screen bodies and connectors, gas lift mandrels, downhole tractors for pulling coiled tubing, tool joints, wired (electrical and/or fiber optic) tool joints, drill in well screens, rotors, stator and/or housings for downhole motors, blades and/or housings for downhole turbines, latches for downhole tools, downhole wireline service tools and other downhole tools have complex configurations and/or asymmetric geometries associated with competing a wellbore. Molds incorporating teachings of the present disclosure may be used to form elastomeric and/or rubber components for such well completion tools. Various well completion tools and/or components may also be formed in accordance with teaching of the present disclosure.
- a mold filled with at least one matrix material and at least one infiltration material (also called a binder), may be heated and cooled to form a matrix bit head.
- at least one matrix material and at least one infiltration material also called a binder
- two or more different types of matrix materials or powders may be disposed in the mold.
- resulting drill bit may sometimes be referred to as a matrix drill bit.
- Binder materials are known including, but not limited to, metallic alloys of copper (Cu), nickel (Ni), magnesium (Mn) , lead (Pb), tin (Sn), cobalt (Co) and silver (Ag) .
- Phosphorous (P) may sometimes be added in small quantities to reduce the liquidity
- matrix materials which may sometimes be referred to as refractory materials, are also known.
- matrix materials may include, but are not limited to, tungsten carbide, monotungsten carbide (WC) , ditungsten carbide ( 2C) , macrocrystalline tungsten carbide, other metal carbides, metal borides, metal oxides, metal nitrides, natural and synthetic diamond, and
- PCD polycrystalline diamond
- metal carbides may include, but are nor limited to, titanium carbide and tantalum carbide. Various mixtures of such materials may also be used.
- Examples of well drilling tools and associated components which may be formed at least in part by molds incorporating the teachings of the present disclosure may include, but are not limited, to, non- retrievable drilling components, aluminum drill bit bodies associated with casing drilling of wellbores, drill string stabilizers, cones for roller cone drill bits, models for forging dyes used to fabricate support arms for roller cone drill bits, arms for fixed reamers, arms for expandable reamers, internal components associated with expandable reamers, sleeves attached to an up hole end of a rotary drill bit, rotary steering tools, logging while drilling tools, measurement while drilling tools, side wall coring tools, fishing spears, washover tools, rotors, stators and/or housing for downhole drilling motors, blades and housings for downhole turbines, and other downhole tools having complex configurations and/or asymmetric geometries associated with forming a ellbore.
- the molds disclosed herein may be used to form elastomeric and/or rubber
- downhole tool and “downhole tools” may also be used to describe well drilling equipment, well drilling tools, well completion equipment, well completion tools and/or associated
- heat flow properties refers generally to the materials properties affecting the transfer and flow of heat energy through a material or across a thermal boundary, such as thermal conductivity and specific heat capacity, as well as, in certain instances, melting/ freezing and evaporation/condensation points, as well as other materials phase changes, regardless of whether such properties are specifically assessed or are assessed indirectly or qualitatively by analysis of some related or proportional measure.
- FIG. 1 shows an example of a fixed cutter drill bit 20 having a plurality of cutter blades 54 arranged around the circumference of a bit head 52.
- the bit head 52 is connected to a shank 30 to form a bit body 50.
- Shank 30 may be connected to the bit head 52 by welding, for example by using laser arc welding to form a weld 39 around, a. weld groove 38, as shown.
- Shank 30 includes or is in turn
- a threaded pin 34 such as an American
- API Petroleum Institute
- cutter blades 54 there are five cutter blades 54, in which pockets or recesses 62, otherwise called “sockets” and “receptacles", are formed.
- Cutting elements 64 otherwise known as inserts, are fixedly installed in each pocket 62, for example by brazing. As the drill bit 20 is rotated in use, it is the cutting elements 64 that come into contact with the
- drilling mud is pumped downhole, through a drill string (not shown ⁇ on which, the drill bit 20 would be supported, and out of nozzles 60 disposed in nozzle openings 53 in the bit head 52.
- a drill string not shown ⁇ on which, the drill bit 20 would be supported
- nozzles 60 disposed in nozzle openings 53 in the bit head 52.
- the drill bit 20 of FIG. 1 is formed as a matrix drill bit, having a matrix bit head 52 as part of matrix bit body 50.
- FIG. 2 shows, schematically, a cross-section through a drill bit of similar construction, and in
- the matrix bit head 52 is formed from a plurality of different matrix materials.
- the matrix bit head 52 is formed about a generally hollow, cylindrical metal blank 36, the metal blank 36 typically being steel.
- a first matrix material 131 is chosen for its fracture resistance characteristics (toughness) and erosion, abrasion and wear resistance.
- First matrix material 131 forms a first zone or layer which corresponds approximately with the exterior portions of composite matrix bit body 50 that contact and remove formation materials during drilling of a wellbore.
- a second matrix material 132 forms an annulus inside the inner diameter 37 of metal blank 36 to form a fluid flow passage 32 that is connected via further flow passages 42 and 44 to respective nozzle openings 58.
- Second matrix material 132 may be primarily used to form interior portions of matrix bit body 50 and exterior portions of matrix bit body 50 which typically do not contact adjacent downhole formation materials while forming a wellbore.
- Second matrix material 132 may also be selected to provide a superior connection to the metal blank 36 than the
- a third matrix material 133 may be used to surround an outside diameter 40 of the metal blank 36.
- Third matrix material 133 is selected so that it may be subsequently machined to provide a desired exterior configuration and transition between matrix bit head 52 and metal shank 36.
- the foregoing relates only to one possible distribution of three matrix materials, and it should, be understood that any number of different matrix materials may in principle be used in the matrix bit head, including only one or two matrix materials or four or more
- the shank 30 can be welded to the metal blank 36 to form matrix bit body 50 after the matrix bit head has been molded onto the metal blank 36, thereby avoiding heat-cycling and deterioration of the materials properties of the shank 30 during heating and cooling of the mold.
- the fluid flow passage 32 extends through shank 30 as well as through the metal blank 36.
- FIGS. 3 and 4 show details of a mold assembly that may be used to manufacture the matrix bit head 52.
- the mold assembly includes a container 300.
- the container 300 may sometimes also be referred to as a
- the container 300 is formed of three parts, a base or end piece 302, a middle ring piece 304 and an upper funnel 306.
- the container may equally be formed of more or fewer parts, for example, where appropriate, by dispensing with the top ring.
- the container may equally be formed as a single part piece. These parts may be connected together by threaded connecting portions, as illustrated. Alternative connections, such as slip fits, may also be used.
- the container 300 may be formed from graphite based materials, boron based materials and/or any other materials having satisfactory heat transfer characteristics, which typically means they should be relatively highly conductive. The material for the
- the mold assembly further includes a mold 200 which is contained in the container 300.
- the mold is formed by a 3D printing process and is then inserted into the base or end piece 302 of the container 300.
- the shape of the outside of the closed end 202 of the mold 200 substantially matches the shape of the inside of the container 300.
- the mold 200 may be inserted into the base or end piece 302 before the ring piece 304 and funnel 306 are connected thereto.
- end piece 302 and ring piece 304 may first be connected, together before the mold 200 is inserted therein. This provides better access to the lower portions of the container 300, and to the mold cavity 252 through the open end 201 of the moid 200, and allows the mold 200 and matrix materials 131, 132, 133 in the container 300 to be built up in stages. This
- the mold 200 may be bowl- shaped, having an inner mold cavity 252 that is
- fluid flow channels 206 may be formed. These channels can be used to circulate a fluid for heating or cooling of the mold 200 and the materials therein. Channels 206 may be connected to a recessed portion or chamber 212 at the closed end 202 of mold 200, to and/or from which heating or cooling fluid may be supplied. A plurality of internal tube ways or flow paths 214 may also be formed within selected portions of mold 200. Flow paths 214 may communicate gases associated with heating and cooling of mold 200 to associated fluid flow channels 206 and/or to exterior portions of mold 200. For some applications one or more openings (not expressly shown) may be formed in container 300 to accommodate communication of heating fluids and/or cooling fluids with chamber 212. The temperature and/or flow rate of such
- heating and/or cooling fluids may be varied to control the heating and cooling process.
- displacements 208 project into the cavity to define the junk slots 56 between cutter blades 54.
- displacements 208 may have been formed as separate pieces and then installed in the mold cavity 252. With the use of 3D printing, however, the displacements 208 may be formed integrally with the mold 200. In a similar manner, whereas it was previously necessary to form a relatively simple mold and then for a skilled mold fabricator to install various other displacements, such other displacements may now be formed as an integral part of the mold 200 by 3D printing. This can result in improved product consistency and process repeatability.
- the crow's foot would normally include a consolidated sand core 150 placed on legs 142 and 144.
- Legs 142 and 144 may also be formed of consolidated sand.
- displacements which make up the crow's foot, provide internal passages through the matrix bit head 52 to the nozzles 60.
- they may be formed by 3D printing in the same way as displacements 208, either as separate components or as an integral part of moid 200.
- the matrix materials 131, 132 and 133 are placed in the mold cavity 252, together with the metal cylindrical blank 36 and the crow's foot.
- Various fixtures may be used to position metal blank 36 within mold assembly 100 at a desired location spaced from first matrix material 131.
- material 160 is then loaded on top of the matrix materials and the metal cylindrical blank, as shown in FIG. 3.
- the entire moid assembly is then pre-heated, before being placed in a furnace.
- the melting point temperature of the infiltration material 160 is exceeded, the infiltration material 160 flows down into the mold cavity, to infiltrate the matrix material.
- the entire mold assembly is then cooled, to allow the infiltration material 160 to solidify.
- the container 300 can then be disassembled, and the matrix bit head 52 is removed from the container.
- the mold 200 will be removed from the container 300,
- the third matrix material 133 may then be machined to obtain the final desired shape of the matrix bit head 52, and shank 30 can be welded onto o e top of the metal cylindrical blank 36 to obtain a matrix bit body 50 (not necessarily in this order) .
- the pockets 62 in the matrix bit head are revealed, as show in FIG. 2.
- Cutting elements 64 may then be installed in each of the pockets 62, for example by brazing.
- One advantage of this type of mold construction is that only the mold 200 has to be destroyed in order to expose the matrix bit head, whilst the container 300 remains intact. This is more economical than in previous mold constructions, in which the mold and container were both fabricated together as a single, body, which would all be destroyed in order to remove the cast matrix bit head from the mold after the molding process. Since the mold printing process is time consuming and the material used to print the mold may be expensive, savings in time and cost may be achieved by using the re-usable container 300 with a
- the container 300 being re-usable, may also be fabricated by a more expensive and/or time-consuming process, such as by CMC (Computer Numerical Control) milling, which may improve the quality and/or durability of the container without compromising overall productivity or increasing overall production costs of the objects being molded therein.
- CMC Computer Numerical Control
- infiltration material 160 can change the overall chemical composition of the infiltration material 160, for example so as to raise the melting point of the infiltration material 160. Furthermore, unless a uniform high temperature is achieved throughout the matrix materials 131, 132 and 133, there may be regions within the matrix material (s) that remain at a lower temperature than other parts of the mold assembly. This can happen, in particular, due to the fact that the mold 200 is typically formed from a clay or sand composition which has a lower thermal conductivity than the material from which the container 300 is made, so that the mold 200 tends to act as a thermal insulator. In addition to this, the matrix materials may not themselves be good thermal conductors.
- a uniform temperature throughout the moid assembly may, in general, be obtained by heating the mold assembly more gradually and/or for a longer period of time, thereby allowing the
- the more usual materials from which mold 200 is printed by the 3D printing process tend to act as thermal insulators. This tends to reduce the speed with which any heating or cooling can be applied to the bottom portion of the mold assembly, in which the mold 200 is disposed, and will tend to cause the lower portion of the mold assembly to heat or cool more slowly than the upper portion, which is the reverse order to that normally desired.
- FIG. 6 An embodiment of such a mold 400 is shown in FIG. 6.
- the mold 400 shown in FIG. 6 is to be installed in a container 300, in the same manner as the mold 200 shown in FIGS. 3, 4 and 5A to 5D. This is illustrated in Fig. 7, which shows the end piece 302 and ring piece 304 of a container 300 in a partially cut-away view to reveal the mold 400 installed therein.
- the mold 400 differs from the mold 200, however, in several notable respects.
- the thickness of the wails of the mold 400 can be minimized down to the minimum thickness that is required in order to maintain the structural integrity of the moid 400, not only under the weight of the matrix materials 131, 132, 133 and infiltration material 160, as well as other components such as the crow's foot and metal cylindrical blank 36, in the mold assembly, but also during fabrication and handling of the moid, including installing the mold 400 in the container 300.
- the thickness of the walls of mold 400 minimized, the insulative effects of the mold are likewise minimized, meaning that the heating and cooling of the materials within the mold can be achieved more rapidly in response to changes in the temperature external to the mold 400.
- characteristics through the mold 400 can, however, be further improved by judiciously selecting materials to be placed within the recesses 406, between the mold 400 and the container 300 into which the mold is installed.
- thermally conductive material is inserted into the recesses 406, then heat will be transmitted more rapidly across the insuiative barrier provided by the mold wall than if the recesses were filled with the printed mold material, which will improve the ability of the manufacturer to control the internal temperature of the moid assembly in response to command inputs.
- Graphite powder and certain types of sand and ceramics are suitable materials that will often have a higher thermal conductivity than the mold material.
- the rate of transfer of heat through the mold walls can be reduced (as compared to if the recesses were filled with the printed mold material) ,
- the manufacturer of the matrix bit head can determine whether to introduce a more thermally insuiative or a more thermally conductive material into the recesses 406.
- different materials may be provided in one, more or all of the individual recesses 406.
- the bottom portions of recesses 406 may be filled with relatively conductive material and the top portions of the recesses 406 filled with relatively insuiative material.
- Recesses 406 will, of course, also be suitable for use as fluid flow channels, in the same manner as fluid flow channels 206 shown in FIGS. 5A to 5D. However, with the additional thermally insulative or conductive materials installed in the recesses and/or due to the thinner mold walls, a more rapid response to the introduction of heating and/or cooling fluids into the recesses 406 can be acquired, thereby resulting in a greater degree of control of
- the heat conducted through the thin walls of the mold 400 in the displacements 408 is delivered closer to the centre of the mold assembly, and so is more effective to heat all the way through the mold assembly, in particular, all the way through matrix materials 131, 132 and 133.
- the mold 400 additionally includes gaps or windows 420 in the upper portion of the mold 400 between adjacent displacements 408. In these regions, there is no printed mold material, such that, when the mold 400 is installed in the container 300, the inner wall of the container 300 will act as the local portion of the mold cavity 452 through these windows 420. The result will be that, in these regions, the material from which the matrix bit head 52 is being molded will be in direct contact with the container 300.
- container 300 is typically formed of a highly conductive material, such as graphite, meaning that thermal control in the region of these windows 420 will in general be greater.
- the portions of the matrix bit body 52 in the region of the windows 420 will in general correspond to the gage portions 570 of the matrix bit head 52 (see FIG. 8) .
- the formation of windows may be desirable in other portions of the mold 400, to bring the matrix and infiltration materials 131, 132, 133, 160 being molded into direct contact with the container 300.
- the container 300 may be shaped on the inside with a surface than will locally form parts of the negative image of the matrix bit head 52, providing that the shape of the inside of the container still permits mold 200 to be removed after molding the matrix bit head 52, such that container 300 can be re-used.
- plaster or sand materials have normally been preferred for the 3D printing of molds
- the mold 400 of Fig. 6 could equally be formed from a relatively more thermally conductive material.
- Graphite powders r boron nitride powders and other matrix material powders which are stable in temperature ranges associated with forming matrix bit bodies may be satisfactorily used. Such powders may have better thermal conductivity and/or better dimensional stability as compared with some sand and/or plaster powders used to form metal casting molds.
- Silica sands, clay sands, quartz sand (Si02), zircon sand and barium, oxide sand are examples of some different
- Zircon sand has been identified, in particular, as having good thermal conduction and other properties that make it useful in forming printed molds.
- different parts of the mold 400 may be molded from different materials in the 3D printing process. Whereas it has
- printed can be varied not only as between adjacent layers of the printed mold 400, bur. also in different regions of each layer of the mold 400. This can be achieved by providing a 3D printing machine capable of printing different materials within different regions of the same layer.
- One way in which, this may be achieved is to first provide a layer of a first material, and to selectively adhere this to underlying layers.
- the non-adhered material is then selectively removed, which may be achieved, for example, by suction or by blowing away the material, or by burning away or otherwise removing the material, for example with a. laser.
- a layer of a second material is then applied, and is selectively adhered to the underlying layers in regions of the same layer to which the first material was previously lust applied, in regions where the first material was not adhered to the underlying layers.
- different materials may be selectively applied in different regions of the same layer by the 3D printing machine, and selectively adhered to the underlying layers in the usual way .
- One available use for this technique is to print portions of the mold 400 which not only have different thermal conductivity, but also to print different portions of the mold which have different electrical conductivity.
- Electrically conductive portions of the mold may be excited by appropriate elect omagnetic radiation, and will then get hot, thereby serving as a heat source for heating the
- heaters HC, HL such as glow bars, induction
- heaters or any other suitable type of heating element may be built into the mold assembly, in order to obtain better and more direct control of the temperature distribution throughout the mold assembly during the heating and/or cooling process.
- the crow' s foot has traditionally been formed, as a separate consolidated sand component which would then be installed in the moid cavity 452, before filling the mold cavity with the matrix materials 131, 132 and. 133, it is, in fact, possible to form the crow's foot using 3D printing.
- the crow' s foot may be printed as one or more separate components, and then installed in the mold cavity 452 of mold 400, or the crow's foot may be printed together with the mold 400, as an integral part of the mold 400.
- This latter alternative may be generally desirable in terms of more efficiently printing the necessary mold components and reducing the number of assembly steps needed to form the mold assembly, although the crow' s foot being integrally molded in this way may inhibit access to the mold for
- the heaters HC, HL in the crow's foot may be
- components of the crow's foot may alternatively include any other known type of heater, either incorporated into a consolidated sand component or incorporated into a printed component of the crow's foot, so as to provide the necessary heat source.
- One form of heat source for transferring heat into the inside of the mold assembly may simply take the form of a relatively highly thermally conductive pathway, for example formed of rods of graphite, by which heat from outside the moid assembly may be rapidly be transferred to the inside of the mold, assembly.
- a relatively highly thermally conductive pathway for example formed of rods of graphite, by which heat from outside the moid assembly may be rapidly be transferred to the inside of the mold, assembly.
- 3D printing will in fact allow the legs 142, 144 of the crow's foot to be formed of complex, non-linear shapes, which may facilitate the ability to build a heater HL into these components. Indeed, providing that the flow of drilling fluid or mud through the fluid flow passageways 42, 44 is not restricted and the structural strength and integrity of the matrix bit head 52 is not unduly
- the shape and position of the legs 142, 144 may be designed specifically to provide for efficient heating of the volume of material in the mold cavity 452 by a heat source in the legs 142, 144.
- Utilizing components of the crow's foot to heat the mold assembly may be advantageous, since it will allow heat to be applied from the center of the mold assembly.
- material, in particular the matrix materials 131, 132 and 133, in the mold cavity 452 can more reliably be heated throughout the volume of the mold cavity 452.
- internal eat sources are provided in combination with external heat sources (i.e., heat sources outside the mold cavity 452), such as when part of the mold 400 is formed from a material that can be excited to generate heat, or when the mold assembly is loaded in a furnace, it becomes possible to achieve improved directional heating and cooling of the mold assembly, by controlling the relative temperatures of the internal and external heat sources. A greater level of control over the heating of the materia.1 in the mold assembly, as well as over the direction of solidification and the rate of
- part of the mold 400 may be formed, from a material that can be electromagnetically excited to generate heat.
- the mold and/or container may be formed to receive similar kinds of other heaters as are contemplated for use in the crow's foot, such as glow bars, induction heaters or any other suitable type of heating element.
- Such heaters may be built into the mold and/or container, or may be assembled rogether therewith when forming the mold assembly. Such heaters provide more direct and responsive heating, and may facilitate the control of directional heating and/or cooling of the materials within the mold cavity during molding of an object.
- heating elements not only into the crow's foot, but also into other parts of the mold assembly.
- glow bars, induction heaters or thermal conduction paths of highly thermally conductive material may be incorporated into the container 300, or they may be installed in the recesses 406 formed in the region of the displacements 408 between the mold 200 and the container 300.
- the container 300 and mold 200 may incorporate a heater into the bottom of the mold assembly, in order to obtain control of the heating process at least in the vertical direction of the mold assembly.
- heating elements may be utilized in the moid assembly, according to need or preference.
- These different layers or regions in the transitional interface between matrix materials 131, 132 and 133 may simply be formed as a number of additional layers, placed in the mold cavity 452 in the usual way. Contemplated, however, is to print the layers of the transitional regions 131t and 132t, by adjusting the composition of the matrix material deposited and printed in each layer.
- the same machine may, in fact, be used to print the matrix material or materials 131, 132 and 133 in the same layers in which the mold material or materials are printed.
- the technique prints the matrix material in each layer of the mold assembly, in a manner that is similar to that proposed above for forming different portions of individual layers of the printed mold using different materials. If such a technique is used, it will, in general, also be preferable to print the crow' s foot at the same time as printing the mold 400 and matrix materials 131, 132 and 133 in the successive layers. In this way, the entire mold assembly to be installed into the container 300, apart from the metal cylindrical blank 36 and the infiltration material 160, may be formed by a single 3D printing process using two or more different materials.
- the bonding between the layers of matrix materials in this example is only needed to allow the 3D printing process to take place, prior to infiltrating the matrix material with the infiltration material 160.
- the layers of matrix material may be bonded by the same printing process that is used to bond the layers of the mold material, or by an alternative process. For example, if a solvent, activator or adhesive is applied to the successive layers of mold material in order to bond the mold material together, the same solvent, activator or adhesive may be applied, in principle from the same source such as an ink jet print head, onto the
- successive layers of matrix material may be used, for example by applying a solvent, activator or adhesive to the successive layers of mold material in order to bond the mold material together and by sintering or partially sintering the
- SLS Selective Laser Sintering
- a 3D printing machine or apparatus having both a print head, for applying a solvent, activator or adhesive, and a laser, for sintering, which can preferably each be directed across the entire surface of each deposited layer of material is desirable.
- Such processes can provide a number of advantages, which include the following.
- the use of printing to deposit matrix materials into the mold cavity 452 during the 3D printing process in which the mold 400 is formed will ensure that matrix material 131, 132, 133 is delivered to every part of the moid cavity 452.
- a 3D printing method of the type described above is known from U.S. Pat. No. 5,433,280 A, column 10, lines 3 to 17, for directly printing a matrix bit body having two different types of matrix powder in each layer.
- the method is used to print a. matrix bit body having hard matrix powder, such as tungsten carbide, a ceramic, or other hard material in a thin region near the outer surfaces of the bit body, whilst the bulk of the bit head is formed of a tough and ductile material inside this outer shell of harder material.
- Alternati ⁇ methods for printing layers of the bit head with two or more types of matrix powder are also contemplated, which may equally be used for printing a mold that includes two or more different materials in individual ones of the printed layers, as well as for simultaneously printing layers including the mold material and the matrix material to be infiltrated.
- U.S. Pat. No. 5,433,280 A explains that the different materials in each printed layer of a bit matrix may instead be selectively deposited in the desired regions in each layer, and then the selectively deposited materials in each layer bonded to the underlying layers .
- a method is also contemplated in which only the outer shell of relatively expensive, hard tungsten carbide or the like is printed, and the shell is then filled with the bulk, tough and ductile powder.
- a similar technique may be adopted for the printing of molds, whereby only the material constituting mold 400 and a thin layer of the hard matrix material 131, in a shell of the matrix bit head, are deposited in each layer, the empty shell being subsequently- filled with the bulk, tough and more ductile powder 132, in the way more normally used for filling a mold with matrix powder.
- Different methods may also be employed for bonding the powder in each layer.
- the method of bonding the deposited layer of powder may involve spraying or printing a binder over the deposited layer, spraying a metal binder over the deposited layer, or spraying an active ingredient over the layer to activate a binder that is already present in or coated on the deposited powder.
- the powder in each layer may alternatively be bonded together by sintering. Similar disclosure and further techniques are also provided in U.S. Pat. No. 5,957,006 A and U.S. Pat. No. 6,200,514 Bl.
- FIG. 12 shows a schematic cross-sectional view through a printed body.
- the body includes mold material M of a moid, which may be the mold 400 of FIG. 6 or a mold similar to mold 200 of FIGS. 5A-5D.
- a shell of matrix material 131 is printed inside of the mold material M, and may be directly adjacent thereto.
- three legs 142, 144, 146 of a crow's foot are optionally formed integrally with the printed body.
- Internal space I may either be printed with a matrix material, for example more tough and ductile material 132, or may be left empty, such that the matrix material 131 forms a shell into which matrix material 132 may later be filled, for example as a powder filled in the cavity I in. the usual way.
- a matrix material for example more tough and ductile material 132
- the matrix material 131 forms a shell into which matrix material 132 may later be filled, for example as a powder filled in the cavity I in. the usual way.
- the boundary between the matrix powder and the mold inner surface may become critical in order to ensure that the mold 400 can eventually be removed from the infiltrated matrix bit head 52.
- a very thin band of yet another material B could be printed between the mold material M and the matrix powder 131 (or 132 or 133) that will form the matrix bit head 52, as a barrier material.
- This additional thin layer can be thought of as a release layer that prevents the infiltration material 160 from infiltrating into the mold 400 when it is melted and used to infiltrate the matrix powders 131, 132, 133 of the matrix bit head 52.
- Barrier material B and/or matrix material 131 could also equally be printed around the legs 142, 144 and 146 of the crow's foot, regardless of whether internal space I is printed with matrix material or this is later filled into the internal space in powder form.
- portions of the mold 400 may be printed that are unconnected to other portions of the mold 400 except by being bonded together through the matrix materials 131, 132, 133. In effect, this allows portions of the mold 400 to be entirely eliminated, i.e., such that the thickness of the mold wall is reduced to zero, whereby the inner surface of the container 300 will serve locally as the inner surface of the mold cavity 450.
- the inner surface of the container 300 may provide the basic shape of the negative image of the matrix bit head 52, whilst the printed parts of the mold are effectively a series of "floating" displacements, merely sufficient to ensure the integrity of the shape of the matrix bit head 52 during the molding process, and to allow the infiltrated matrix bit head 52 to be removed from the container 300 without destroying container 300.
- the present inventors also propose a further line of development in the selective deposition of mold and matrix materials.
- the skilled reader will appreciate that until now all 3D printing processes make up the mold or matrix in successive horizontal layers, building up either from the top or the bottom of the mold or bit matrix,
- One particular issue would be the difficulty in printing layers up to and. around an internal component of the mold assembly, such as the metal cylindrical blank 36. In a horizontally-layered structure, it would be necessary to print the matrix material and nearby parts of the mold 400 or of the crow' s foot so as to define a recess into which the metal cylindrical blank can be installed before the infiltration material 160 is added. Similar issues can arise if heater elements are to be disposed in the crow' s foot or other printed components or parts of the mold 400.
- the mold 400 may be formed as two or more separate pieces that can be assembled together and installed in the container 300.
- the mold 400 might be formed as two separate, substantially semi-cylindrical bodies 400a and 400b, which may be clamped or otherwise positioned and held together around the metal blank 36.
- the metal blank 36 shown in FIG. 11 is formed with projections 36p extending into each of the cutter blades 54, in order to provide strength and structural support to the inside of the cutter blades 54.
- Such an arrangement may require the mold 400 to be formed from a number of separate pieces.
- container 300 may be formed as a printed unitary body, it is also possible to install various types of displacement
- consolidated sand including, but not limited to, consolidated sand and/or graphite.
- resins may be satisfactorily used to form consolidated sand.
- Such mold inserts, displacements and/or preforms may be used to form various features of the matrix bit head, including, but not limited to, fluid flow
- cutter drill bits, drag bits and other types of rotary drill bits may be satisfactorily formed from a bit body molded in accordance with teachings of the present disclosure.
- the present invention is not limited to drill bit 20 or any individual features discussed in relation to the specific embodiments .
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Abstract
Priority Applications (5)
Application Number | Priority Date | Filing Date | Title |
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US13/990,308 US20130333950A1 (en) | 2010-11-29 | 2011-11-25 | Heat flow control for molding downhole equipment |
CA2819031A CA2819031C (fr) | 2010-11-29 | 2011-11-25 | Ameliorations dans la regulation de flux de chaleur pour le moulage d'un equipement de fond |
AU2011335124A AU2011335124A1 (en) | 2010-11-29 | 2011-11-25 | Improvements in heat flow control for molding downhole equipment |
EP11799646.2A EP2646185A2 (fr) | 2010-11-29 | 2011-11-25 | Améliorations dans la régulation de flux de chaleur pour le moulage d'un équipement de fond |
US14/962,896 US10399258B2 (en) | 2010-11-29 | 2015-12-08 | Heat flow control for molding downhole equipment |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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GB1020235.6 | 2010-11-29 | ||
GB1020235.6A GB2485848B (en) | 2010-11-29 | 2010-11-29 | Improvements in heat flow control for molding downhole equipment |
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US13/990,308 A-371-Of-International US20130333950A1 (en) | 2010-11-29 | 2011-11-25 | Heat flow control for molding downhole equipment |
US14/962,896 Division US10399258B2 (en) | 2010-11-29 | 2015-12-08 | Heat flow control for molding downhole equipment |
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WO2012072513A2 true WO2012072513A2 (fr) | 2012-06-07 |
WO2012072513A3 WO2012072513A3 (fr) | 2013-04-04 |
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US (2) | US20130333950A1 (fr) |
EP (3) | EP2716390A3 (fr) |
AU (1) | AU2011335124A1 (fr) |
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2011
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- 2011-11-25 CA CA2819031A patent/CA2819031C/fr not_active Expired - Fee Related
- 2011-11-25 AU AU2011335124A patent/AU2011335124A1/en not_active Abandoned
- 2011-11-25 WO PCT/EP2011/071038 patent/WO2012072513A2/fr active Application Filing
- 2011-11-25 EP EP13198927.9A patent/EP2716390A3/fr not_active Withdrawn
- 2011-11-25 EP EP15155032.4A patent/EP2910322A1/fr not_active Withdrawn
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Cited By (5)
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CN103222528A (zh) * | 2013-05-06 | 2013-07-31 | 兰雄兵 | 3d打印设备及其送料系统 |
US10124531B2 (en) | 2013-12-30 | 2018-11-13 | Ut-Battelle, Llc | Rapid non-contact energy transfer for additive manufacturing driven high intensity electromagnetic fields |
US9650537B2 (en) | 2014-04-14 | 2017-05-16 | Ut-Battelle, Llc | Reactive polymer fused deposition manufacturing |
WO2017037713A1 (fr) * | 2015-09-02 | 2017-03-09 | Stratasys Ltd. | Moule imprimé 3d pour moulage par injection |
US11198238B2 (en) | 2016-10-18 | 2021-12-14 | Stratasys Ltd. | 3D printing of a structure for injection molding |
Also Published As
Publication number | Publication date |
---|---|
GB2485848A (en) | 2012-05-30 |
CA2819031C (fr) | 2015-11-17 |
WO2012072513A3 (fr) | 2013-04-04 |
EP2716390A3 (fr) | 2014-07-30 |
CA2819031A1 (fr) | 2012-06-07 |
US20130333950A1 (en) | 2013-12-19 |
AU2011335124A1 (en) | 2013-06-20 |
GB2485848B (en) | 2018-07-11 |
EP2646185A2 (fr) | 2013-10-09 |
EP2910322A1 (fr) | 2015-08-26 |
EP2716390A2 (fr) | 2014-04-09 |
GB201020235D0 (en) | 2011-01-12 |
US20160089821A1 (en) | 2016-03-31 |
US10399258B2 (en) | 2019-09-03 |
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